Battery and battery manufacturing method

ABSTRACT

A battery includes an electrode body and an internal terminal attached to the electrode body. The electrode body includes positive electrode sheets, negative electrode sheets, and separators. The positive electrode sheets and the negative electrode sheets are alternately stacked in a stacking direction, with each separator interposed between associated adjacent ones of the positive electrode sheets and the negative electrode sheets. The positive electrode sheets and the negative electrode sheets each include a collector foil. At least either portions of the collector foils of the positive electrode sheets or the negative electrode sheets are protruded beyond the separators in one direction. The protruded portions of the collector foils are piled in a stack in the stacking direction. The internal terminal includes a connector connected to the stack of the protruded portions of the collector foils. The stack of the protruded portions is bent around a base end of the protruded portions of the collector foils.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. application Ser. No. 16/276,146, filed Feb. 14, 2019, which claims the benefit of priority to Japanese Patent Application No. 2018-025956 filed on Feb. 16, 2018. The entire contents of each of which is incorporated herein by reference in its entirety.

BACKGROUND

The present disclosure relates to batteries and battery manufacturing methods.

JP 2013-254628 A discloses a secondary battery including a “stacked”electrode body and a rectangular battery case. The electrode body includes a plurality of positive electrode sheets, a plurality of negative electrode sheets, and a plurality of separators. The positive electrode sheets and the negative electrode sheets are stacked, with each separator interposed between associated adjacent ones of the positive electrode sheets and the negative electrode sheets. A direction in which the positive electrode sheets and the negative electrode sheets are stacked corresponds to the thickness direction of the electrode body. The electrode body is housed in the battery case. The electrode body is provided with a first collector assembly. The first collector assembly includes collectors of the positive electrode sheets that are put together at a first end of the electrode body in the thickness direction and bent toward a second end of the electrode body in the thickness direction. The first collector assembly is connected with a rectangular plate collector terminal by ultrasonic welding. The electrode body is further provided with a second collector assembly. The second collector assembly includes collectors of the negative electrode sheets that are put together at the first end of the electrode body in the thickness direction and bent toward the second end of the electrode body in the thickness direction. The second collector assembly is connected with another rectangular plate collector terminal by ultrasonic welding.

JP 2016-100323 A discloses a battery including an electrode body and a battery case. Widthwise ends of the electrode body are provided with collectors. The collectors are each connected to an associated terminal attached to a lid of the battery case in a rivet-like manner.

SUMMARY

A battery mounted on a motor vehicle is required to enable the vehicle to travel for a long distance in an EV traveling mode with a single full charge. This makes it necessary to increase the capacity of the battery. Because an installation space for such a vehicle-mounted battery is limited, the battery is required to have a high volume energy density in order to increase the capacity of the battery. To increase the volume energy density, a dead space in a battery case is preferably as small as possible. The inventors of the present disclosure conducted research to find out a compact collector structure for an electrode body with the aim of reducing a dead space in a battery case.

An embodiment of the present disclosure provides a battery including an electrode body and an internal terminal attached to the electrode body. The electrode body includes a plurality of positive electrode sheets, a plurality of negative electrode sheets, and a plurality of separators. The positive electrode sheets and the negative electrode sheets are alternately stacked in a stacking direction, with each separator interposed between associated adjacent ones of the positive electrode sheets and the negative electrode sheets. The positive electrode sheets and the negative electrode sheets each include a collector foil. At least either portions of the collector foils of the positive electrode sheets or portions of the collector foils of the negative electrode sheets are protruded beyond the separators in one direction. The protruded portions of the collector foils are piled in a stack in the stacking direction. The internal terminal includes a connector connected to the stack of the protruded portions of the collector foils. The stack of the protruded portions of the collector foils connected to the connector is bent around a base end of the protruded portions of the collector foils.

This embodiment provides a compact collector structure for the protruded portions of the collector foils of the electrode body. Such a compact collector structure reduces a dead space in a battery case.

The connector of the internal terminal may have a flat plate shape. With the stack of the protruded portions of the collector foils bent around the base end of the protruded portions of the collector foils, the connector connected to the stack of the protruded portions may be located outward of the base end. The internal terminal preferably further includes a case coupling attached to a case component. The case coupling is preferably disposed on an end of the connector such that the case coupling extends along a peripheral edge of the electrode body. This provides a compact collector structure extending along the peripheral edge of the electrode body.

The internal terminal may include a positive electrode internal terminal and a negative electrode internal terminal.

Portions of the collector foils of the positive electrode sheets are preferably protruded beyond first widthwise ends of the separators. The protruded portions of the collector foils of the positive electrode sheets are preferably piled in a stack in the stacking direction. The positive electrode internal terminal preferably includes a positive electrode connector. The positive electrode connector of the positive electrode internal terminal is preferably connected to the stack of the protruded portions of the collector foils of the positive electrode sheets. The stack of the protruded portions of the collector roils of the positive electrode sheets connected to the positive electrode connector is preferably bent around a base end of the protruded portions of the collector foils of the positive electrode sheets.

Portions of the collector foils of the negative electrode sheets are preferably protruded beyond second widthwise ends of the separators. The protruded portions of the collector foils of the negative electrode sheets are preferably piled in a stack in the stacking direction. The negative electrode internal terminal preferably includes a negative electrode connector. The negative electrode connector of the negative electrode internal terminal is preferably connected to the stack of the protruded portions of the collector foils of the negative electrode sheets. The stack of the protruded portions of the collector foils of the negative electrode sheets connected to the negative electrode connector is preferably bent around a base end of the protruded portions of the collector foils of the negative electrode sheets.

This provides a compact positive electrode collector structure for the portions of the collector foils protruded from the first widthwise ends of the separators, and a compact negative electrode collector structure for the portions of the collector foils protruded from the second widthwise ends of the separators.

Another embodiment of the present disclosure provides a battery manufacturing method including the steps of: a) preparing an electrode body; b) preparing an internal terminal; and c) attaching the internal terminal to the electrode body.

The electrode body prepared in step a) includes a plurality of positive electrode sheets, a plurality of negative electrode sheets, and a plurality of separators. The positive electrode sheets and the negative electrode sheets are alternately stacked in a stacking direction, with each separator interposed between associated adjacent ones of the positive electrode sheets and the negative electrode sheets. The positive electrode sheets and the negative electrode sheets each include a collector foil. At least either portions of the collector foils of the positive electrode sheets or portions of the collector foils of the negative electrode sheets are protruded beyond the separators in one direction.

The internal terminal prepared in step b) induces a connector to be attached to the collector foils.

Step c) includes the sub-steps of: c1) piling the protruded portions of the collector foils in a stack in the stacking direction; c2) connecting the connector of the internal terminal to the stack of the protruded portions of the collector foils; and c3) bending the stack of the protruded portions of the collector foils connected to the connector. The stack of the protruded portions is bent around a base end of the protruded portions of the collector foils.

This embodiment provides a battery having a compact collector structure.

The stacking direction may include a first direction and a second direction opposite to the first direction. Sub-step c1) may involve bringing a first plate and a second plate into contact with the protruded portions of the collector foils in the first direction and the second direction, respectively, such that the protruded portions of the collector foils are brought to an intermediate location in the stacking direction so as to pile the protruded portions of the collector foils in a stack.

During or before the bending of the stack of the protruded portions of the collector foils connected to the connector, sub-step c3) may involve removing one or the first and second plates that is located opposite to a direction in which the stack of the protruded portions is to be bent.

The battery manufacturing method may further include the steps of: d) preparing a case component; e) preparing an external terminal; and f) attaching the internal terminal to the case component, with the internal terminal attached to the electrode body in step c).

The case component prepared in step d) preferably includes an attachment hole through which the internal terminal is to be attached to the case component. The internal terminal prepared in step b) preferably Includes a shaft to be inserted through the attachment hole. The shaft is preferably disposed on a portion of the internal terminal extending from the connector. The external terminal prepared in step e) preferably includes a connector to be connected with an end of the shaft inserted through the attachment hole. Step f) preferably involves: inserting the shaft of the internal terminal through the attachment hole of the case component, with an insulator disposed in the attachment hole; and connecting the connector of toe external terminal to the shaft of the internal terminal inserted through the attachment hole.

The internal terminal may thus he attached to the case component after the internal terminal is attached to the electrode body.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial perspective view of a battery 10, with an electrode body 11 and an internal terminal 12 attached to a lid 14 b of a battery case 14.

FIG. 2 is a partial side view of the battery 10, with the internal terminal 12 attached to the lid 14 b of the battery case 14.

FIG. 3 is an exploded view of the battery 10, illustrating components of the battery 10, such as the internal terminal 12, the lid 14 b of the battery case 14, and an external terminal 13.

FIG. 4 is an exploded perspective view of the electrode body 11.

FIG. 5 is a plan view of the electrode body 12, Illustrating sub-steps c1) and c2) of a battery manufacturing method according to an embodiment of the present disclosure.

FIG. 6 is a plan view of the electrode body 11, with the internal terminal 12 attached to a stack, of protruded portions of collector foils 12 a in sub-step c2).

FIG. 7 is a side view of the electrode body 11, with the internal terminal 12 attached to the stack of the protruded portions of the collector foils 11 a in sub-step c2).

FIG. 8 is a plan view of the electrode body 11, illustrating sub-step c3) involving bending the stack of the protruded portions of the collector foils 11 a 1 connected to a connector 12 a.

FIG. 9 is a plan view of the electrode body 11, with the stack of the protruded portions of the collector foils 11 a bent in sub-step c3).

FIG. 10 is a side view of the electrode body 11, with the stack of the protruded portions of the collector foils 11 a bent in sub-step c3).

DETAILED DESCRIPTION

Batteries and battery manufacturing methods according to embodiments of the present disclosure will be described below. The embodiments described below are naturally not intended to limit the present invention in any way. Unless otherwise specified, the present invention la not limited to the embodiments described below. Each of the accompanying drawings is a schematic illustration and thus does not necessarily depict actual shapes or sizes. Components or elements having the same functions may be identified by the same reference signs, and description thereof will be omitted when deemed redundant. The reference signs may be omitted in detailed illustrations. The reference signs U, D, R, L, F, and Rr in the drawings respectively represent up, down, right, left, front, and rear. These directions are defined merely for the sake of convenience and are not intended to limit in any way how a battery 10 may be installed.

FIG. 1 is a partial perspective view of the battery 10, with an electrode body 11 and an internal terminal 12 attached to a lid 14 b of a battery case 14. In FIG. 1, the lid 14 b of the battery case 14, to which the electrode body 11 and the internal terminal 12 are attached, is located away from an opening 14 a 1 of a case body 14 a. FIG. 2 is a partial side view of the battery 10, with the internal terminal 12 attached to the lid 14 b of the battery case 14. FIG. 3 is an exploded view of the battery 10, illustrating components of the battery 10, such as the internal terminal 12, the lid 14 b of the battery case 14, and an external terminal 13.

As illustrated in FIG. 1, the battery 10 includes the electrode body 11, the internal terminal 12, the external terminal 13, the battery case 14, an insulator 15, and a bolt terminal 16.

As illustrated in FIG. 1, the battery case 14 includes the case body 14 a and the lid 14 b. The case body 14 a includes a housing space in which the electrode body 12 is to be housed. The case body 14 a is a rectangular exterior case that includes the opening 14 a 1 defined by the four surfaces of the case body 14 a. The lid 14 b is a rectangular lid to be fitted to the opening 14 a 1 of the battery case 14. As illustrated in FIG. 3, the lid 14 b is provided with an attachment hole 14 b 1 through which the internal terminal 12 is to be attached to the lid 14 b. In one example, the case body 14 a and the lid 14 b are each preferably made of aluminum or an aluminum alloy, such as1000 series aluminum or 3000 series aluminum. The electrode body 11 is covered with an insulator, such as an insulating film (not illustrated). The electrode body 11 thus insulated is housed in the battery case 14.

A method for manufacturing the battery 10 includes the steps of:

-   -   a) preparing the electrode body 11;     -   b) preparing the internal terminal 12;     -   c) attaching the internal terminal 12 to the electrode body 11;     -   d) preparing the lid 14 b that is a case component;     -   e) preparing the external terminal 13; and     -   f) attaching the internal terminal 12 to the lid 14 b, with the         internal terminal 12 attached to the electrode body 11.

FIG. 4 is an exploded perspective view of the electrode body 11.

As illustrated in FIG. 4, the electrode body 11 prepared in step a) includes a plurality oi; positive electrode sheets 11 a, a plurality of negative electrode sheets 11 b, and a plurality of separators 11 c. The positive electrode sheets 11 a and the negative electrode sheets 11 b are alternately stacked in a stacking direction, with each separator 11 c interposed between associated adjacent ones of the positive electrode sheets 11 a and the negative electrode sheets 11 b. The positive electrode sheets 11 a each include a collector foil 11 a 1. The negative electrode sheets 11 b each include a collector foil 11 b 1.

In one example, each positive electrode sheer. 11 a includes: the collector foil 11 a 1 (which is aluminum foil in the present embodiment) having predetermined width and thickness; a positive electrode active material layer 11 a 3 containing a positive electrode active material; and a positive electrode active material layer-free portion 11 a 2 having a constant width. The positive electrode active material layer-free portion 11 a 2 is defined on an end of the collector foil 11 a 1 located on one side in the width direction of the collector foil 11 a 1.. The positive electrode active material layer 11 a 3 is defined on both surfaces of the collector foil 11 a 1 except the positive electrode active material layer-free portion 11 a 2. For a lithium ion secondary battery, examples of the positive electrode active material include a lithium transition metal composite material that is capable of releasing lithium ions during charging and absorbing lithium ions during discharge. Examples of the positive electrode active material include various generally known materials in addition to such a lithium transit ion metal composite material. The positive electrode active material is thus not limited to any particular material.

In one example, each negative electrode sheet 11 b includes: the collector foil 11 b 1 (which is copper foil in the present embodiment) having predetermined width and thickness; a negative electrode active material layer 11 b 3 containing a negative electrode active material; and a negative electrode active material layer-free portion 11 b 2 having a constant width. The negative electrode active material layer-free portion 11 b 2 is defined on an end of the collector foil 11 b 1 located on one side in the width direction of the collector foil 11 b 1. The negative electrode active material layer 11 b 3 is defined on both surfaces of the collector foil 11 b 1 except the negative electrode active material layer-free portion 11 b 2. For a lithium ion secondary battery, examples of the negative electrode active material include natural graphite chat is capable of storing lithium ions during charging and releasing the lit hi urn ions during discharge. Examples of the negative electrode active material include various generally known materials in addition to such natural graphite. The negative electrode active material is thus not limited to any particular material.

Examples of the separators 11 c to be used include a porous resin sheet that has required heat resistance and allows an electrolyte to pass therethrough. Examples of the separators 11 c include various other sheets. The separators lie are thus not limited to any particular type of sheet.

In the present embodiment, a portion (or more specifically, the positive electrode active material layer-free portion 11 a 2) of the collector foil 11 a 1 of each positive electrode sheet 11 a is protruded beyond a first widthwise end of each separator 11 c. A portion (or acre specifically, the negative electrode active material layer-free portion 11 b 2) of the collector foil 11 b 1 of each negative electrode sheet 11 b is protruded beyond a second widthwise end of each separator 11 c. The second widthwise end of each separator 11 c is located opposite to the first widthwise end of each separator 11 c. In the present embodiment, portions of the collector foils 11 a 1 of the positive electrode sheets 11 a are protruded beyond the separators 11 c in one direction, and portions of the collector foils 11 b 1 of the negative electrode sheets 11 b are protruded beyond the separators 11 c in the other direction. A structure to attach the internal terminal 12 to the collector foils 11 a 1 of the positive electrode sheets 11 a may be different from a structure to attach the internal terminal 12 to the collector foils 11 b 1 of the negative electrode sheets 11 b. Thus, either portions of the collector foils 11 a 1 of the positive electrode sheets 11 a or portions of the collector foils 11 b 1 of the negative electrode sheets 11 b, which have the structures described below, are preferably protruded beyond the separators 11 c in one direction.

As illustrated in FIGS. 2 and 3, portions of the collector foils 11 a 1 of the battery 10 protruded beyond the separators 11 c are piled in a stack in the stacking direction (i.e., in the thickness direction of the protruded portions of the collector foils 11 a 1). The stacking direction includes a first direction and a second direction opposite to the first direction.

FIGS. 2 and 3 illustrate a portion of the battery 10 where the internal terminal 12 is attached to the collector foils 11 a 1 of the positive electrode sheets 11 a. The following description discusses a structure to attach the internal terminal 12 to the collector foils 11 a 1 of the positive electrode sheets 11 a. In the present embodiment, another internal terminal 12 (i.e., a negative electrode internal terminal) is attached to the collector foils 11 b 1 of the negative electrode sheets 11 b in a manner similar to that in which the internal terminal 12 (i.e., a positive electrode internal terminal) is attached to the collector foils 11 a 1 of the positive electrode sheets 11 a.

FIG. 4 illustrates the electrode body 11 having a “stacked structure” in which the positive electrode sheets 11 a and the negative electrode sheets 11 b are alternately stacked, with each separator 11 c interposed between associated adjacent ones of the positive electrode sheets 11 a and the negative electrode sheets 11 b. The electrode body 11 is not limited to the structure illustrated in FIG. 4. Although not illustrated, the electrode body 11 may be a “wound type” electrode body. The wound type electrode body includes a strip-shaped positive electrode sheet, a strip-shaped negative electrode sheet, and a strip-shaped separator. The positive electrode sheet and the negative electrode sheet are stacked, with the separator interposed between the positive electrode sheet and the negative electrode sheet. The positive electrode sheet, the negative electrode sheet, and the separator are wound into a fiat shape. A portion (or more specifically, a positive electrode active material layer-free portion) of a collector foil of the positive electrode sheet is protruded beyond a first end of the separator located on one side along a winding axis. A portion (or more specifically, a negative electrode active material layer-free portion) of a collector foil of the negative electrode sheet is protruded beyond a second end of the separator located on the other side along the winding axis. The wound type electrode body wound into a flat shape has round corners. The protruded portions of the collector foils of the positive and negative electrode sheets, which define the round corners, may each be cut into pieces.

As illustrated in FIGS. 2 and 3, the internal terminal 12 prepared in step b) includes a connector 12 a and a case coupling 12 b. The connector 12 a is attached to the collector foils 11 a 1. The case coupling 12 b is attached to the lid 14 b that is a case component. The case coupling 12 b is provided with a shaft 12 c.

The connector 12 a of the internal terminal 12 preferably has a flat plate shape. The case coupling 12 b is preferably a substantially rectangular plate. The case coupling 12 b is preferably disposed on an end at the connector 12 a. The shaft 12 c is preferably inserted through the attachment hole 14 b 1 of the lid 14 b.

Step c5 involves attaching the internal terminal 12 to the electrode body 11. Step c) includes the sub-steps of:

-   -   c1) piling the protruded portions of the collector foils 11 a 1         in a stack;     -   c2) connecting the connector 12 a of the internal terminal 12 to         the stack of the protruded portions of the collector foils 11 a         1; and     -   c3) bending the stack of the protruded portions of the collector         foils 11 a 1 connected to the connector 12 a.

The stack of the protruded portions of the collector foils 11 a 1 is bent around a base end of the protruded portions of the collector foils 11 a 1.

FIG. 5 is a plan view of the electrode body 11, illustrating sub-steps c1) and c2) of the battery manufacturing method according to the present embodiment.

As illustrated in FIG. 5, sub-step c1) involves piling the protruded portions of Die collector foils 11 a 1 in a stack in the stacking direction (see FIG. 5). In other words, the stacking direction (see FIG. 4) corresponds to the thickness direction of the protruded portions of the collector foils 11 a 1.

As illustrated in FIG. 5, sub-step c1) involves using a first plate 41 and a second plate 42 so as to pile the protruded portions of the collector foils 11 a 1 In a stack. Using the first plate 41 and the second plate 42, the protruded portions of the collector foils 11 a 1 are piled in a stack in the stacking direction.

The first plate 41 is brought into contact with the protruded portions of the collector foils 11 a 1 in the first direction so as to define the base end of the protruded portions of the collector foils 11 a 1.

The second plate 42 is brought Into contact with the protruded portions of the collector foils 11 a 1 in the second direction so as to define the base end of the protruded portions of the collector foils 11 a 1.

The first plate 41 and the second plate 42 bring the protruded portions of the collector foils 11 a 1 to an intermediate location in the stacking direction so as to pile the protruded portions of the collector foils 11 a 1 in a stack

The electrode body 11 is preferably disposed at a predetermined location. The first plate 41 is preferably brought into contact with the protruded portions of the collector foils 11 a 1 in the first direction such chat the protruded portions of the collector foils 11 a 1 are brought to the intermediate location in the stacking direction so as to define the base end of the protruded portions of the collector foils 11 a 1. The second plate 42 is preferably brought into contact with the protruded portions of the collector foils 11 a 1 in the second direction such that the protruded portions of the collector foils 11 a 1 are brought to the intermediate location in the stacking direction so as to define the base end of the protruded portions of the collector foils 11 a 1. The protruded portions of the collector foils 11 a 1 are thus brought to the intermediate location and piled in a stack as illustrated in FIG. 5.

As illustrated in FIG. 5, sub-step c2) involves connecting the connector 12 a of the internal terminal 12 to the stack of the protruded portions of the collector foils 1 a 1.

In the present embodiment, the protruded portions of the collector foils 11 a 1 are brought to the intermediate location in the stacking direction and piled in a stack using the first plate 41 and the second plate 42 as illustrated in FIG. 5. The connector 12 a of the internal terminal 12 is connected to the protruded portions of the collector foils 11 a 1 brought to the intermediate location in the sticking direction. The connector 12 a of the internal terminal 12 say be connected to the protruded portions of the collector foils 11 a 1 by resistance welding, ultrasonic welding, or laser welding, for example.

As illustrated in FIG. 5, the connector 12 a of the internal terminal 12 is brought into contact with one side of the stack of the protruded portions of the collector foils 11 a 1 located at the intermediate location in the stacking direction. A backup plate 43 is brought into contact with the other side of the stack of the protruded portions of the collector foils 11 a 1. A welding tip 44 is brought into contact with the connector 12 a of the internal terminal 12 and a welding tip 45 is brought into contact with the backup plate 43, such that the connector 12 a and the backup plate 43 are sandwiched between the welding tips 44 and 45. In this state, a current, is passed through the welding tips 44 and 45. The connector 12 a of the internal terminal 12, the stack of the protruded portions of the collector foils 11 a 1, and the backup plate 43 are thus resistance-welded to each other. The backup plate 43 may not be used if the connector 12 a of the internal terminal 12 and the protruded pore ions of the collector foils 11 a 1 are adequately weldable to each other without the backup plate 43.

FIG. 6 is a plan view of the electrode body 11, with the internal terminal 12 attached to the stack of the protruded portions of the collector foils 11 a in sub-step c2). FIG. 7 is a side view of the electrode body 11, with the internal terminal 12 attached to the stack of the protruded portions of the collector foils 11 a in sub-step c2).

Sub-step c3) involves bending the stack of the protruded portions of the collector foils 11 a 1 connected to the connector 12 a. The stack of the protruded portions of the collector foils 11 a 1 is bent around the base end of the protruded portions of the collector foils 11 a 1.

FIG. 8 is a plan view of the electrode body 11, illustrating sub-step c3) involving bending the stack of the protruded portions of the collector foils 11 a 1 connected to the connector 12 a.

During or before the bending of the stack of the protruded portions of the collector foils 11 a 1 connected to the connector 12 a, sub-step c3) involves removing one of the first and second plates 41 and 42 that is located opposite to a direction in which the stack of the protruded portions is to be bent.

In the example illustrated in FIG. 8, the stack of the protruded portions of the collector foils 11 a 1 connected to the connector 12 a is bent such that the backup plate 43 approaches the second plate 42. This pulls the protruded portions of the collector foils 11 a 1 located adjacent to the connector 12 a. In the example illustrated in FIG. 6, the first plate 41, which has been used to bring the protruded portions of the collector foils 11 a 1 to the intermediate location, is preferably removed with appropriate timing. The first plate 41 may be removed during or before the bending of the stack, of the protruded portions of the collector foils 11 a 1 connected to the connector 12 a.

Removal of the first plate 41 removes the pressure applied to the protruded portions of the collector foils 11 a 1 by the first plate 41. This makes it unlikely that the protruded portions of the collector foils 11 a 1 will be broken during sub-step c3). The backup plate 43 is preferably removed with appropriate timing during sub-step c3). Although not illustrated, the stack of the protruded portions of the collector foils 11 a 1 connected to the connector 12 a may alternatively be bent in a direction in which the protruded portions of the collector foils 11 a 1 are connected to the connector 12 a. In this case, the second plate 42, which has been used to bring the protruded portions of the collector foils 11 a 1 to the intermediate location, is preferably removed before removal of the first plate 41.

FIG. 9 is a plan view of the electrode body 11, with the stack of the protruded portions of the collector foils 11 a bent in sub-step c3). FIG. 10 is a side view of the electrode body 11, with the stack of the protruded portions of the collector foils 11 a bent in sub-step c3).

As illustrated in FIG. 9, the connector 12 a of the internal terminal 12 is disposed along the base end of the protruded portions of the collector foils 11 a 1. Thus, as illustrated in FIG. 10, the connector 12 a of the internal terminal 12 is attached to the stack of the protruded porticos of the collector foils 11 a 1 compactly in the direction of protrusion of the collector foils 11 a 1 from the electrode body 11 (i.e., in the width direction of the electrode body 11 in the present embodiment).

As illustrated in FIG. 9, the connector 12 a of the internal terminal 12 is preferably designed such that the connector 12 a does not protrude beyond the electrode body 11 in the stacking direction, with the stack of the protruded portions of the collector foils 11 a 1 bent around the base end of the protruded portions of the collector foils 11 a 1. As illustrated in FIG. 2, the case coupling 12 b of the internal terminal 12 is preferably designed such that the case coupling 12 b is located inward of the inner surface of the lid 14 b.

As illustrated in FIGS. 6 and 7, the case coupling 12 b may be oriented in any direction before the stack of the protruded portions of the collector foils 11 a 1 connected to the connector 12 a is bent around the base end of the protruded portions of the collector foils 11 a 1, unless any particular limitation is imposed.

With the stack of the protruded portions of the collector foils 11 a 1 bent around the base end of the protruded portions of the collector foils 11 a 1, the connector 12 a connected to the stack of the protruded portions is preferably located outward of the base end. The internal terminal 12 preferably includes the case coupling 12 b to be attached to the lid 14 b that is a case component. The case coupling 12 b is preferably disposed on the end of the connector 12 a that extends beyond the base end. The case coupling 12 b preferably extends along the peripheral edge of the electrode body 11 from the end of the connector 12 a.

In other words, the case coupling 12 b of the internal terminal 12 preferably extends along the upper surface of the electrode body 11 (i.e., a surface of the electrode body 11 defined by the upper edges of the positive electrode sheets 11 a and the negative electrode sheets 11 b slacked) as illustrated in FIGS. 2, 3, and 10. This enables the components of the internal terminal 12 to be disposed along the peripheral edge of the electrode body 11, so that the internal terminal 12 is at least partially disposed in a gap between the electrode body 11 and the lid 14 b of the battery case 14. Consequently, the present embodiment provides a compact collector structure for the electrode body 11.

Although the above description has discussed how the internal terminal 12 is attached to the collector foils 11 a 1 of the positive electrode sheets 11 a, another internal terminal may similarly be attached to the collector foils 11 b 1 of the negative electrode sheets 11 b (see FIG. 4).

The battery 10 preferably includes the positive electrode internal terminal 12 and a negative electrode internal terminal (not illustrated) similar in structure to the internal terminal 12. Portions of the collector foils 11 b 1 of the negative electrode sheets 11 b (see FIG. 4) are preferably protruded beyond the second widthwise end of each separator 11 c. The protruded portions of the collector foils 11 b 1 are preferably piled in a stack in the stacking direction. The connector 12 a (see FIG. 6) of the negative electrode internal terminal is preferably connected to the stack of the protruded portions of the collector foils 11 b 1 of the negative electrode sheets 11 b. The stack of the protruded portions of the collector foils 11 b 1 of the negative electrode sheets 11 b (which is connected to the connect or 12 a of the negative electrode internal terminal) is preferably bent around a base end of the protruded portions of the collector foils 11 b 1 of the negative electrode sheets 11 b (see FIG. 9). The connector 12 a of the negative electrode internal terminal is attached to the stack of the protruded portions of the collector foils 11 b 1 of the negative electrode sheets 11 b in a manner similar to that illustrated In FIG. 6. The stack of the protruded portions of the collector foils 11 b 1 of the negative electrode sheets 11 b (which is attached to the connector 12 a of the negative electrode internal terminal) is bent in a manner similar to that illustrated in FIG. 9.

As illustrated in FIG. 4, portions of the collector foils 11 a 1 of the positive electrode sheets 11 a are protruded beyond the first widthwise end of each separator 11 c, and portions of the collector foils 11 b 1 of the negative electrode sheets 11 b are protruded beyond the second widthwise end of each separator 11 c. The portions of the collector foils 11 a 1 of the positive electrode sheets 11 a protruded beyond the first widthwise end of each separator 11 c are piled in a stack in the thickness direction. The connector 12 a of the positive electrode internal terminal 12 is connected to the stack of the protruded portions of the collector foils 11 a 1. The stack of the protruded portions of the collector foils 11 a 1 (which is connected to the connector 12 a of the positive electrode internal terminal 12) is bent around the base end of the protruded portions of the collector foils 11 a 1. The portions of the collector foils 11 b 1 of the negative electrode sheets 11 b protruded beyond the second widthwise end of each separator 11 c are piled in a stack, in the thickness direction. The connector 12 a of the negative electrode internal terminal is connected to the stack of the protruded portions of the collector foils 11 b 1. The stack of the protruded portions of the collector foils 11 b 1 (which is connected to the connector 12 a of the negative electrode internal terminal) is bent around the base end of the protruded portions of the collector foils 11 b 1. Consequently, the present embodiment provides a compact positive electrode collector structure adjacent to the first widthwise ends of the separators 11 c of the electrode body 11 and a compact negative electrode collector structure adjacent, to the second widthwise ends of the separators 11 c of the electrode body 11.

The connector 12 a of the positive electrode internal terminal 12 is connected to the stack of the portions of the collector foils 11 a 1 of the positive electrode sheets 11 a protruded beyond the first widthwise ends of the separators 11 c, and the stack of the protruded portions of the collector foils 11 a 1 (which is connected to the connector 12 a of the positive electrode internal terminal 12) is bent around the base end of the protruded portions of the collector foils 11 a 1 (see FIGS. 9 and 10). Although not illustrated, the connector 12 a of the negative electrode internal terminal is connected to the stack of the portions of the collector foils 11 b 1 of the negative electrode sheets 11 b (see FIG. 4) protruded beyond the second width wise ends of the separators 11 c, and the stack of the protruded portions of the collector foils 11 b 1 (which is connected to the connector 12 a of the negative electrode internal terminal) is bent in a mariner similar to that illustrated in FIGS. 9 and 10. This reduces the gap between the positive electrode active material layer 11 a 3 of each positive electrode sheet 11 a and the negative electrode active material layer 11 b 3 of the adjacent negative electrode sheet 11 b (see FIG. 4) on both sides in the width direction of the associated separator 11 c. Thus, a capillary phenomenon makes it likely that an electrolyte will be held between each positive electrode sheet 11 a and the adjacent negative electrode sheet 11 b on both sides in the width direction of the associated separator 11 c. Consequently, “drying up” of an electrolyte is unlikely to occur on both sides in the width direction of each separator 11 c.

As illustrated in FIGS. 9 and 10, the stack of the protruded portions of the collector foils 11 a 1 (which is connected to the connector 12 a of the internal terminal 12) is bent around the base end of the protruded portions of the collector foils 11 a 1. In this state, the case coupling 12 b of the internal terminal 12 is attached to the lid 14 b that is a case component (see FIG. 3).

Step d) involves preparing the lid 14 b that is a case component. The lid 14 b is preferably provided with the attachment hole 14 b 1 through which the shaft 12 c extending from the case coupling 12 b of the internal terminal 12 is to be inserted.

Step e) involves preparing the external terminal 13. The external terminal 13 preferably includes a connector 13 a to be connected with an end of the shaft 12 c of the internal terminal 12 inserted through the attachment hole 14 b 1 of the lid 14 b.

Step f) involves attaching the internal terminal 12 to the lid 14 b, with the internal terminal 12 attached to the electrode body 11 in step c).

In one example, step f) involves inserting the shaft 12 c of the internal terminal 12 through the attachment hole 14 b 1 of the lid 14 b, with the insulator 15 disposed in the attachment hole 14 b 1. Step f) then preferably involves connecting the connector 13 a of the external terminal 13 to the shaft 12 c of the internal terminal 12 inserted through the attachment hole 14 b 1.

In the present embodiment, the shaft 12 c of the internal terminal 12 attached to the electrode body 11 is inserted through the attachment hole 14 b 1 of the lid 14 b as illustrated in FIGS. 2 and 3. The shaft 12 c is inserted through the attachment hole 14 b 1 from inside the lid 14 b, with gaskets 15 a and 15 b interposed between the lid 14 b end the case coupling 12 b of the internal terminal 12. The gaskets 15 a and 15 b are components of the insulator 15.

At a location outside the lid 14 b, an insulating member 15 c is fitted to the shaft 12 c of the internal terminal 12 attached to the lid 14 b. The insulating member 15 c is a component of the insulator 15. The external terminal 13 is provided with: an insertion hole 13 b through which the shaft 12 c of the internal terminal 12 is to be inserted; and an insertion hole 13 c through which the bolt terminal 16 is to be inserted. The present embodiment involves inserting the shaft 12 c of the internal terminal 12 through the insertion hole 13 b and inserting the belt terminal 16 through the insertion hole 13 c so as to attach the bolt terminal 16 and the external terminal 13 onto the insulating member 15 c as illustrated in FIG. 2.

As illustrated in FIG. 3, the connector 13 a includes a swaging member 17. As illustrated in FIG. 2, the swaging member 17 is attached to the end of the shaft 12 c of the internal terminal 12 inserted through the insertion hole 13 b of the external terminal 13. This prevents the external terminal 13 fitted to the shaft 12 c of the internal terminal 12 from being disengaged from the shaft 12 c of the internal terminal 12. The external terminal 13 is preferably at least partially welded to the shaft 12 c of the internal terminal 12 so as to provide conductivity between the internal terminal 12 and the external terminal 13.

The connector 13 a that connects the external terminal 13 to the shaft 12 c of the internal terminal 12 is not limited to the above-described structure. Alternatively, the external terminal 13 may be provided with a boss through which the shaft 12 c of the internal terminal 12 is to be inserted, and the boss may be radially swaged by electromagnetic welding. The shaft. 12 c of the internal terminal 12 may thus be secured and connected to the boss of the external terminal 13.

As described above, the positive electrode internal terminal 12 and the negative electrode internal terminal, which are attached to the electrode body 11, are further attached to the lid 14 b. This attaches the electrode body 11 to the lid 14 b. In this state, the electrode body 11 is preferably housed in the case body 14 a such that the opening 14 a 1 of the case body 14 a is covered with the lid 14 b. The peripheral edge of the lid 14 b is then preferably welded to the opening 14 a 1 of the case body 14 a.

Various embodiments of the present disclosure have been described thus far. Unless otherwise specified, the embodiments of the present disclosure described herein do not limit the present invention.

In the above-described embodiment, the collector toils 11 a 1 of the positive electrode sheets 11 a are similar in collector structure to the collector foils 11 b 1 of the negative electrode sheets 11 b. Alter natively, the collector foils 11 a 1 of the positive electrode sheets 11 a may be different in collector structure from the collector foils 11 b 1 of the negative electrode sheets 11 b. In such a case, at least either portions of the collector foils 11 a 1 of the positive electrode sheets 11 a or portions of the collector foils 11 b 1 of the negative electrode sheets 11 b are preferably protruded beyond the separators 11 c in one direction, and the protruded portions are preferably piled in a stack in the stacking direction. At least either the positive electrode internal terminal 12 or the negative electrode internal terminal preferably includes the connector 12 a to be connected to the stack of the protruded portions. The stack of the protruded portions connected to the connector 12 a is preferably bent around the base end of the protruded portions. Thus, at least either the collector foils 11 a 1 of the positive electrode sheets 11 a or the collector foils 11 b 1 of the negative electrode sheets 11 b may have the collector structure described above.

The shapes of the components of the battery 10, such as the internal terminal 12, the external terminal 13, and the insulator 15, are not limited to the shapes illustrated in the drawings. Various changes may be made to the shapes of the components of the battery 10. Although the internal terminal 12 is attached to the lid 14 b that is a case component, the internal terminal 12 may alternatively be attached to the case body 14 a that is another case component. 

What is claimed is:
 1. A battery manufacturing method comprising the steps of: a) preparing an electrode body; b) preparing an internal terminal; and c) attaching the internal terminal to the electrode body, wherein the electrode body prepared in step a) includes a plurality of positive electrode sheets, a plurality of negative electrode sheets, and a plurality of separators, the positive electrode sheets and the negative electrode sheets are alternately stacked in a stacking direction, with each separator interposed between associated adjacent ones of the positive electrode sheets and the negative electrode sheets, the positive electrode sheets and the negative electrode sheets each include a collector foil, at least either portions of the collector foils of the positive electrode sheets or portions of the collector foils of the negative electrode sheets are protruded beyond the separators in one direction, the internal terminal prepared in step b) includes a connector to be attached to the collector foils, and step c) includes the sub-steps of c1) piling the protruded portions of the collector foils in a stack in the stacking direction, c2) connecting the connector of the internal terminal to the stack of the protruded portions of the collector foils, and c3) bending the stack of the protruded portions of the collector foils connected to the connector, the stack of the protruded portions being bent around a base end of the protruded portions of the collector foils.
 2. The battery manufacturing method according to claim 1, wherein the stacking direction includes a first direction, and a second direction opposite to the first direction, and sub-step c1) involves bringing a first plate and a second plate into contact with the protruded portions of the collector foils in the first direction and the second direction, respectively, such that the protruded portions of the collector foils are brought to an intermediate location in the stacking direction so as to pile the protruded portions of the collector foils in a stack.
 3. The battery manufacturing method according to claim 2, wherein during or before the bending of the stack of the protruded portions of the collector foils connected to the connector, sub-step c3) involves removing one of the first and second plates that is located opposite to a direction in which the stack of the protruded portions is to be bent.
 4. The battery manufacturing method according to claim 1, further comprising the steps of: d) preparing a case component; e) preparing an external terminal; and f) attaching the internal terminal to the case component, with the internal terminal attached to the electrode body in step c), wherein the case component prepared in step d) includes an attachment hole through which the internal terminal is to be attached to the case component, the internal terminal prepared in step b) includes a shaft to be inserted through the attachment hole, the shaft being disposed on a portion of the internal terminal extending from the connector, the external terminal prepared in step e) includes a connector to be connected with an end of the shaft inserted through the attachment hole, and step f) involves inserting the shaft of the internal terminal through the attachment hole of the case component, with an insulator disposed in the attachment hole, and connecting the connector of the external terminal to the shaft of the internal terminal inserted through the attachment hole. 